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OM-716 199 981A January 2001 Processes Resistance Spot Welding Description MSW-41, MSW-41T, MSW-42, MSW-42T, And LMSW-52, LMSW-52T Portable Resistance Spotwelders Visit our website at www.MillerWelds.com From Miller to You Thank you and congratulations on choosing Miller. Now you can get the job done and get it done right. We know you don’t have time to do it any other way. That’s why when Niels Miller first started building arc welders in 1929, he made sure his products offered long-lasting value and superior quality. Like you, his customers couldn’t afford anything less. Miller products had to be more than the best they could be. They had to be the best you could buy. Today, the people that build and sell Miller products continue the tradition. They’re just as committed to providing equipment and service that meets the high standards of quality and value established in 1929. This Owner’s Manual is designed to help you get the most out of your Miller products. Please take time to read the Safety precautions. They will help you protect yourself against potential hazards on the worksite. We’ve made installation and operation quick and easy. With Miller you can count on years of reliable service with proper maintenance. And if for some reason the unit needs repair, there’s a Troubleshooting section that will Miller is the first welding help you figure out what the problem is. The equipment manufacturer in parts list will then help you to decide which the U.S.A. to be registered to the ISO 9001 Quality System exact part you may need to fix the problem. Standard. Warranty and service information for your particular model are also provided. Working as hard as you do – every power source from Miller is backed by the most hassle-free warranty in the business. Miller offers a Technical Manual which provides more detailed service and parts information for your unit. To obtain a Technical Manual, contact your local distributor. Your distributor can also supply you with Welding Process Manuals such as SMAW, GTAW, GMAW, and GMAW-P. Miller Electric manufactures a full line of welders and welding related equipment. For information on other quality Miller products, contact your local Miller distributor to receive the latest full line catalog or individual catalog sheets. To locate your nearest distributor or service agency call 1-800-4-A-Miller, or visit us at www.MillerWelds.com on the web. TABLE OF CONTENTS SECTION 1 – SAFETY PRECAUTIONS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1. Symbol Usage . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Resistance Spot Welding Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Additional Symbols for Installation, Operation, and Maintenance . . . . . . . . . . . . . . . . . . . . . . . 1-4. Principal Safety Standards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. EMF Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION . . . . . . . . . . . . . . . . . . . . . 1-1. Signification des symboles . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-2. Dangers liés au soudage par points . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance 1-4. Principales normes de sécurité . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5. Information sur les champs électromagnétiques . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 2 – INTRODUCTION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1. Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 3 – INSTALLATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-1. Installing Or Dressing Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-2. Installing Or Cleaning Tongs . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-3. Adjusting Tong And Hand Lever Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-4. Installing Handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-5. Mounting Control Box . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-6. Connecting Input Power (T Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3-7. Connecting Input Power (Non-T Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 4 – OPERATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1. Controls (T Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-2. Controls (Non-T Models) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 5 – MAINTENANCE AND TROUBLESHOOTING . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-1. Routine Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-2. Overload Protection For 220 Volts Model . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3. Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 6 – ELECTRICAL DIAGRAMS . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . SECTION 7 – PARTS LIST . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . Chart 7-1. Spot Welder Tips . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 1 2 2 2 3 3 3 4 4 4 5 5 5 5 7 8 9 10 10 11 12 12 12 13 13 13 13 15 18 22 SECTION 1 – SAFETY PRECAUTIONS - READ BEFORE USING spotom _nd_11/99 1-1. Symbol Usage Means Warning! Watch Out! There are possible hazards with this procedure! The possible hazards are shown in the adjoining symbols. Y Marks a special safety message. . Means “Note”; not safety related. This group of symbols means Warning! Watch Out! possible ELECTRIC SHOCK, MOVING PARTS, and HOT PARTS hazards. Consult symbols and related instructions below for necessary actions to avoid the hazards. 1-2. Resistance Spot Welding Hazards Y The symbols shown below are used throughout this manual to call attention to and identify possible hazards. When you see the symbol, watch out, and follow the related instructions to avoid the hazard. The safety information given below is only a summary of the more complete safety information found in the Safety Standards listed in Section NO TAG. Read and follow all Safety Standards. Y Only qualified persons should install, operate, maintain, and repair this unit. Y During operation, keep everybody, especially children, away. D D D D D SPOT WELDING can cause fire. Sparks can fly off from the weld. The flying sparks, hot workpiece, and hot equipment can cause fires, burns, and explosions. D D D D D D D D D D D Protect yourself and others from flying sparks and hot metal. Do not spot weld where flying sparks can strike flammable material. Remove all flammables within 35 ft (10.7 m) of the weld. If this is not possible, tightly cover them with approved covers. Be alert that welding sparks can easily go through small cracks and openings to adjacent areas. Watch for fire, and keep a fire extinguisher nearby. Do not spot weld on closed containers such as tanks or drums. Do not weld where the atmosphere may contain flammable dust, gas, or liquid vapors (such as gasoline). Remove any combustibles, such as a butane lighter or matches, from your person before doing any welding. After completion of work, inspect area to ensure it is free of sparks, glowing embers, and flames. Do not exceed the equipment rated capacity. Use only correct fuses or circuit breakers. Do not oversize or bypass them. D D D D D FLYING SPARKS can cause injury. Very often sparks fly off from the joint area. D Wear approved face shield or safety goggles with side shields. D D ELECTRIC SHOCK can kill. D D D Touching live electrical parts can cause fatal shocks or severe burns. The input power circuit and machine internal circuits are also live when power is on. Incorrectly installed or improperly grounded equipment is a hazard. Do not touch live electrical parts. Wear dry, hole-free insulating gloves and body protection. Disconnect input power before installing or servicing this equipment. Lockout/tagout input power according to OSHA 29 CFR 1910.147 (see Safety Standards). Properly install and ground this equipment according to this manual and national, state, and local codes. Check and be sure that input power cord ground wire is properly connected to ground terminal in disconnect box or that cord plug is connected to a properly grounded receptacle outlet – always double-check the supply ground before applying power. When making input connections, attach the grounding conductor first – double-check connections. Keep cords dry, free of oil and grease, and protected from hot metal and sparks. Frequently inspect input power cord and ground conductor for damage or bare wiring – replace immediately if damaged – bare wiring can kill. Check ground conductor for continuity. Turn off all equipment when not in use. For water-cooled equipment, check and repair or replace any leaking hoses or fittings. Do not use any electrical equipment if you are wet or in a wet area. Use only well-maintained equipment. Repair or replace damaged parts at once. Wear a safety harness if working above floor level. Keep all panels, covers, and guards securely in place. Wear protective garments such as oil-free, flame-resistant leather gloves, heavy shirt, cuffless trousers, high shoes, and a cap. Synthetic material usually does not provide such protection. Protect others in nearby areas by using approved flame-resistant or noncombustible fire curtains or shields. Have all nearby persons wear safety glasses with side shields. HOT METAL can cause burns. Wear gloves or allow cooling period before servicing tongs or tips. D Always wear welding-type, insulated gloves when using this equipment. D D Do not touch workpiece, tips, or tongs with bare hands. Allow tongs and tips to cool before touching. OM-716 Page 1 D D D D D MOVING PARTS can cause injury. FUMES can be hazardous. The tong tips, tongs, and linkages move during operation. Coatings, cleaners, paints, and platings can produce fumes when welded. Breathing these fumes can be hazardous to your health. Keep away from moving parts. Keep away from pinch points. Do not put hands between tips. Keep all guards and panels securely in place. OSHA and/or local codes may require additional guarding to suit the application. D D D D D Do not breathe the fumes. If inside, ventilate the area and/or use exhaust at the weld to remove fumes. In confined spaces, use an approved air-supplied respirator. Do not weld on coated metals, such as galvanized, lead, or cadmium plated steel, unless the coating is removed from the weld area, the area is well ventilated, or if necessary, while wearing an air-supplied respirator. The coatings and any metals containing these elements can give off toxic fumes if welded. Read the Material Safety Data Sheets (MSDSs) and the manufacturer’s instructions for metals, coatings, and cleaners. 1-3. Additional Symbols For Installation, Operation, And Maintenance FIRE OR EXPLOSION hazard. D Do not install or place unit on, over, or near combustible surfaces. D Do not install or operate unit near flammables. D Do not overload building wiring – be sure power supply system is properly sized, rated, and protected to handle this unit. FALLING EQUIPMENT can cause injury. D Use equipment of adequate capacity to lift the unit. D Have two people of adequate physical strength lift portable units. MAGNETIC FIELDS can affect pacemakers. D Pacemaker wearers keep away. D Wearers should consult their doctor before going near resistance spot welding operations. OVERUSE can cause OVERHEATING. D Allow cooling period; follow rated duty cycle. D Reduce duty cycle before starting to weld again. D Secure unit during transport so it cannot tip or fall. FLYING METAL or DIRT can injure eyes. D Wear approved safety glasses with side shields or wear face shield. 1-4. Principal Safety Standards Safety in Welding and Cutting, ANSI Standard Z49.1, from American Welding Society, 550 N.W. LeJeune Rd, Miami FL 33126 Safety and Health Standards, OSHA 29 CFR 1910, from Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. National Electrical Code, NFPA Standard 70, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Code for Safety in Welding and Cutting, CSA Standard W117.2, from Canadian Standards Association, Standards Sales, 178 Rexdale Boulevard, Rexdale, Ontario, Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, ANSI Standard Z87.1, from American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting And Welding Processes, NFPA Standard 51B, from National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 1-5. EMF Information Considerations About Welding And The Effects Of Low Frequency Electric And Magnetic Fields Welding current will cause electromagnetic fields. There has been and still is some concern about such fields. However, after examining more than 500 studies spanning 17 years of research, a special blue ribbon OM-716 Page 2 committee of the National Research Council concluded that: “The body of evidence, in the committee’s judgment, has not demonstrated that exposure to power-frequency electric and magnetic fields is a humanhealth hazard.” However, studies are still going forth and evidence continues to be examined. SECTION 1 – CONSIGNES DE SÉCURITÉ – LIRE AVANT UTILISATION spotom _nd_Fre_4/97 1-1. Signification des symboles Signifie Mise en garde ! Soyez vigilant ! Cette procédure présente des risques de danger ! Ceux-ci sont identifiés par des symboles adjacents aux directives. Y Identifie un message de sécurité particulier. . Signifie NOTA ; n’est pas relatif à la sécurité. Ce groupe de symboles signifie Mise en garde ! Soyez vigilant ! Il y a des risques de danger reliés aux CHOCS ÉLECTRIQUES, aux PIÈCES EN MOUVEMENT et aux PIÈCES CHAUDES. Reportezvous aux symboles et aux directives ci-dessous afin de connaître les mesures à prendre pour éviter tout danger. 1-2. Dangers liés au soudage par points Y Les symboles représentés ci-dessous sont utilisés dans ce manuel pour attirer l’attention et identifier les dangers possibles. Lorsque vous rencontrez un symbole, prenez garde et suivez les instructions afférentes pour éviter tout risque. Les instructions en matière de sécurité indiquées ci-dessous ne constituent qu’un sommaire des instructions de sécurité plus complètes fournies dans la normes de sécurité énumérées dans la Section 1-4. Lisez et observez toutes les normes de sécurité. D D D Y Seul un personnel qualifié est autorisé à installer, faire fonctionner, entretenir et réparer cet appareil. Y Pendant le fonctionnement, maintenez à distance toutes les personnes, notamment les enfants de l’appareil. D D LE SOUDAGE PAR POINTS peut provoquer un incendie. Des étincelles peuvent être projetées de la soudure. La projection d’étincelles ainsi que les pièces et équipements chauds peuvent provoquer des incendies, des brûlures et des incendies. D D D D D D D D D D D Protégez-vous, ainsi que toute autre personne travaillant sur les lieux, contre les étincelles et le métal chaud. Ne soudez pas par points dans un endroit où des étincelles peuvent tomber sur des substances inflammables. Déplacez toute matière inflammable se trouvant dans un périmètre de 10 m de la pièce à souder. Si cela est impossible, couvrez-les de housses approuvées et bien ajustées. Des étincelles du soudage peuvent facilement passer dans d’autres zones en traversant de petites fissures et des ouvertures. Afin d’éliminer tout risque de feu, soyez vigilant et gardez toujours un extincteur à portée de main. Ne soudez pas par points sur un récipient fermé tel un réservoir ou un bidon. Ne soudez pas si l’air ambiant est chargé de particules, gaz, ou vapeurs inflammables (vapeur d’essence, par exemple). Avant de souder, retirez toute substance combustible de vos poches telles qu’un briquet au butane ou des allumettes. Une fois le travail achevé, assurez-vous qu’il ne reste aucune trace d’étincelles incandescentes ni de flammes. Ne dépassez pas la puissance permise de l’équipement. Utiliser exclusivement des fusibles ou coupe-circuits appropriés. Ne pas augmenter leur puissance; ne pas les ponter. D D D D D D LES ÉTINCELLES VOLANTES risquent de provoquer des Des étincelles peuvent jaillir de la soudure. blessures. D Portez une visière ou des lunettes de sécurité avec des écrans latéraux approuvées. D D UNE DÉCHARGE ÉLECTRIQUE peut entraîner la mort. Ne touchez pas aux pièces électriques sous tension. Portez des gants isolants et des vêtements de protection secs et sans trous. Portez un équipement de protection: gants en cuir résistant au feu, chemise épaisse, pantanlons sans revers, chaussures de sécurité et casquette. Les matériaux synthétiques ne garantissent pas une bonne protection. Protégez les autres occupants du local à l’aide d’un rideau ou d’un écran ignifuge approprié. Assurez-vous que ces personnes portent des lunettes de sécurité avec protections latérales. LE MÉTAL CHAUD peut provoquer des brûlures. Le fait de toucher à une pièce électrique sous tension peut donner une décharge fatale ou entraîner des brûlures graves. L’alimentation d’entrée et les circuits internes de l’appareil sont également actifs lorsque le poste est sous tension. Un poste incorrectement installé ou inadéquatement mis à la terre constitue un danger. D D Coupez l’alimentation d’entrée avant d’installer l’appareil ou d’effectuer l’entretien. Verrouillez ou étiquetez la sortie d’alimentation selon la norme OSHA 29 CFR 1910.147(reportez-vous aux Principales normes de sécurité). Installez le poste correctement et mettez-le à la terre conformément aux consignes de ce manuel et aux normes nationales, provinciales et locales. Assurez-vous que le fil de terre du cordon d’alimentation est correctement relié à la borne de terre du sectionneur ou que la fiche du cordon est branchée à une prise correctement mise à la terre – vous devez toujours vérifier la mise à la terre avant toute mise sous tension. Avant d’effectuer les connexions d’alimentation, vous devez connecter en premier lieu le fil de terre - contrôlez les connexions. Les câbles doivent être exempts d’humidité, d’huile et de graisse; protégez-les contre les étincelles et les pièces métalliques chaudes. Assurez-vous régulièrement que les câbles d’alimentation et de masse ne sont pas endommagés ou dénudé par endroit. Remplacez-les immédiatement si c’est le cas : un câble dénudé peut provoquer la mort. Contrôlez la continuité de la mise à la terre. L’équipement doit être hors tension lorsqu’il n’est pas utilisé. Dans le cas d’équipements refroidis par eau, contrôlez les conduites et raccords; remplacez-les s’ils présentent des fuites. N’utilisez pas d’équipement électrique si vous êtes mouillé ou dans une zone humide. Utilisez uniquement un équipement en bonne condition. Réparez ou remplacez immédiatement toute pièce endommagée. Portez un harnais de sécurité si vous devez travailler au-dessus du sol. Maintenez en place les panneaux, couvercles et protections de sécurité. Portez des gants ou laissez refroidir les électrodres avant de procéder à l’entretien. D Portez toujours de gants de soudeur lorsque vous utilisez cet équipement. D D Ne touchez pas les pièces ni les eléctrodes avec les mains. Laissez les électrodes refroidir avant de les toucher. OM-716 Page 3 DES ORGANES MOBILES peuvent provoquer des blessures. LES FUMÉES peuvent être dangereuses. Pendant le soudage, les bras et électrodes se déplacent. D D D D Ne pas s’approcher des organes mobiles. Ne pas s’approcher des points de coincement. Ne placez pas les mains entre les électrodes. Maintenez en place les panneaux et protections de sécurité. Lors du soudage, les revêtements, produits de nettoyage, peintures et placages peuvent dégager des fumées. Leur inhalation peut être dangereuse. D D D D D Ne respirez pas les fumées. Si vous soudez à l’intérieur, ventilez le local et/ou ayez recours à une ventilation aspirante installée près de la soudure pour évacuer les fumées. Dans des lieux exigus, utilisez un appareil respiratoire approprié. Ne pas souder des métaux munis d’un revêtement, tels que l’acier galvanisé, plaqué en plomb ou au cadmium à moins que le revêtement n’ait été enlevé dans la zone de soudure, que l’endroit soit bien ventilé, et si nécessaire, en portant un respirateur à alimentation d’air. Les revêtements et tous les métaux renfermant ces éléments peuvent dégager des fumées toxiques en cas de soudage. Veuillez lire les consignes de sécurité et les instructions du fabricant pour les métaux, revêtements et produits de nettoyage. 1-3. Dangers supplémentaires en relation avec l’installation, le fonctionnement et la maintenance Risque D’INCENDIE OU D’EXPLOSION. LES CHAMPS MAGNÉTIQUES peuvent affecter les stimulateurs cardiaques. D Ne pas placer l’appareil sur, au-dessus ou à proximité de surfaces infllammables. D Ne pas installer ni faire fonctionner l’appareil à proximité de substances inflammables. D Porteurs de stimulateur cardiaque, restez à distance. D Les porteurs d’un stimulateur cardiaque doivent d’abord consulter leur médecin avant de s’approcher des opérations de soudage par points. D Ne pas surcharger l’installation électrique – s’assurer que l’alimentation est correctement dimensionnée et protégée avant de mettre l’appareil en service. L’EMPLOI EXCESSIF peut SURCHAUFFER L’ÉQUIPEMENT. LA CHUTE DE L’ÉQUIPEMENT peut blesser. D Prévoir une période de refroidissement; respecter le cycle opératoire nominal. D Réduire le facteur de marche avant de poursuivre le soudage. D Utiliser un engin d’une capacité appropriée pour soulever l’appareil. D Faites déplacer les équipements portables par deux personnes dotées d’une force suffisante. D Durant le transport, immobilisez l’appareil pour éviter qu’il ne bascule. DES PIÈCES DE MÉTAL ou DES SALETÉS peuvent provoquer des blessures aux yeux. D Porter des lunettes de sécurité à coques latérales ou un écran facial. 1-4. Principales normes de sécurité Safety in Welding and Cutting, norme ANSI Z49.1, de l’American Welding Society, 550 N.W. Lejeune Rd, Miami FL 33126 Safety and Health Sandards, OSHA 29 CFR 1910, du Superintendent of Documents, U.S. Government Printing Office, Washington, D.C. 20402. National Electrical Code, NFPA Standard 70, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. Règles de sécurité en soudage, coupage et procédés connexes, norme CSA W117.2, de l’Association canadienne de normalisation, vente de normes, 178 Rexdale Boulevard, Rexdale (Ontario) Canada M9W 1R3. Safe Practices For Occupation And Educational Eye And Face Protection, norme ANSI Z87.1, de l’American National Standards Institute, 1430 Broadway, New York, NY 10018. Cutting and Welding Processes, norme NFPA 51B, de la National Fire Protection Association, Batterymarch Park, Quincy, MA 02269. 1-5. Information sur les champs électromagnétiques Données sur le soudage électrique et sur les effets, pour l’organisme, des champs magnétiques basse fréquence L’extrait suivant est tiré des conclusions générales du document intitulé Biological Effects of Power Frequency Electric & Magnetic Fields – Background Paper, OTA-BP-E-53 (Washington DC : U.S. Government Printing Office, mai 1989), publié par le Office of Technology Assessment du Congrès américain : «... il existe maintenant d’abondantes données scientifiques compilées à la suite d’expériences sur la cellule ou d’études sur des animaux et des humains, qui montrent clairement OM-716 Page 4 que les champs électromagnétiques basse fréquence peuvent avoir des effets sur l’organisme et même y produire des transformations. Même s’il s’agit de travaux de très grande qualité, les résultats sont complexes. Cette démarche scientifique ne nous permet pas d’établir un tableau d’ensemble cohérent. Pire encore, elle ne nous permet pas de tirer des conclusions finales concernant les risques éventuels, ni d’offrir des conseils sur les mesures à prendre pour réduire sinon éliminer les risques éventuels». (Traduction libre) SECTION 2 – INTRODUCTION 2-1. Specifications AC Input Voltage 50/60 Hz 1-Phase Work Capacity Combined Thickness Mild Steel Rated Output At 50% Duty Cycle* MSW-41T 110 1/8 in (3.2 mm) MSW-42T 220 LMSW-52T 220 Model Welder Dimensions Weight Height Width Length Net Ship 1.5 kVA 6 in (152 mm) 4-1/2 in (114 mm) 13 in (330 mm) 34 lb (15.4 kg) 38 lb (17.2 kg) 1/8 in (3.2 mm) 1.5 kVA 6 in (152 mm) 4-1/2 in (114 mm) 13 in (330 mm) 34 lb (15.4 kg) 38 lb (17.2 kg) 3/16 in (4.7 mm) 2.5 kVA 6 in (152 mm) 4-1/2 in (114 mm) 16 in (406 mm) 42 lb (19.1 kg) 45 lb (20.4 kg) *Based on 10 second time period; means unit can weld for 5 seconds out of each 10 second time period. Model Tong Length MSW-41, 41T 6 in (152 mm) Input Volts 12 in (305 mm) MSW-42, 42T 18 in (457 mm) 6 in (152 mm) 12 in (305 mm) 110 Output Amps ±10% 5500 4500 LMSW-52, 52T 18 in (457 mm) 6 in (152 mm) 12 in (305 mm) 220 3600 5500 18 in (457 mm) 220 4500 3600 6750 5800 4850 SECTION 3 – INSTALLATION 3-1. Installing Or Dressing Tips A. Installing Tips 1 2 3 Threaded Tip Tip With Hexhead Screw Tong Coat threads with supplied heat sink compound and install tip onto tong. Do not overtighten. 2 1 3 OR Tools Needed: 3/16 in 3 9/16 in Ref. ST-800 155-B / Ref. ST-800 154 OM-716 Page 5 B. Dressing The Tips 1 2 3 New Tip Used Tip Requiring Dressing Dressing Method – Keep top diameter same as a new tip. d = <1/8 in (3.2 mm) diameter for 1.5 kVA models; 5/32 in (4 mm) for 2.5 kVA models Tools Needed: 1 d d 3 2 OR OM-716 Page 6 3-2. Installing Or Cleaning Tongs Y Turn off and unplug welder. Y OSHA and/or local codes may require additional guarding to suit the application. . Be sure tong ends are clean and not corroded before installing. Clean tongs with fine steel wool. Bottom Tong: 1 2 3 Bottom Tong Hole In Spatter Guard Bottom Tong Securing Screws (4) Loosen the four screws. If needed, use a rubber mallet to loosen tong. Slide tong into bottom tong holder as far as possible, and position so that tip is pointing straight up. 6 5 Loosely tighten screws. Top Tong: 4 5 6 4 Top Tong Top Tong Holder/Pivot Casting Top Tong Securing Screws (4) Loosen the four screws. If needed for removal, use a rubber mallet to loosen tong. 2 Slide tong into pivot casting as far as necessary, so that tip mates with bottom tip when tongs are closed. 3 7 1 Loosely tighten screws. 7 Tips Adjust tong positions to line up centers of tips as shown. Tighten screws. Tong Alignment 4 4 7 7 1 1 Front View Side View Tools Needed: 3/16 in 9/16 in Fine Steel Wool ST-800 155-A / Ref. ST-800 154-A OM-716 Page 7 3-3. Adjusting Tong And Hand Lever Pressure 2 1 4 6 3 5 7 Tools Needed: 9/16, 11/16 in Ref. ST-800 156 Y Turn off and unplug welder. Y Excessive tong pressure can damage tips. Do not use tongs as a clamp or vice to hold workpiece together. If the two pieces of material to be welded do not make good contact at the point of the intended weld, clamp material to provide good contact between surfaces. . Tong pressure is adjustable, and must be checked and/or set before operation. Correct tong pressure is necessary to create a quality weld and to prevent damage to tips. Too much tong pressure causes the weld nugget to dimple and material to OM-716 Page 8 splash out around the nugget area. If tong pressure is too weak, parts are loose when the tongs close, severe arcing occurs between workpieces, and no weld can be made. 1 Front Nut 2 Rear Nut 3 Pivot Casting 4 Hand Lever 5 Tongs To increase tong pressure, loosen front nut. The farther the front nut is turned out, the greater the pressure on the tips when the hand lever is closed. Turn the rear nut up to the pivot casting to lock the position. To decrease tong pressure, loosen the rear nut and turn the front nut up to the pivot casting. 6 Machine Screw The farther down the screw is turned, the farther the hand lever will close. Adjustment of this screw will determine if the tongs lock on the material, or just pull up tight. Adjust screw to allow lever to be raised easily after the weld has been completed. 7 Hex Nut To adjust pressure needed to push down hand lever, turn the hex nuts located on each side of the pivot casting. 3-4. Installing Handle MSW 41 And 41T Models 1 2 3 MSW 42, 52, 42T, And 52T Models 2 1 1 2 Tools Needed: Ref. ST-802 056 7/16, 3/8 in Y 1 2 3 Turn off and unplug welder. Wodden Handle Handle Bolt Brackets (41 And 41T Models Only) Install handle onto the spot welder as shown above. For 42, 52, 42T, and 52T Models, install handle onto either side as desired for either right-hand or left-hand use. OM-716 Page 9 3-5. Mounting Control Box Push-in slots are provided on rear of box for wall mounting if desired. The slots will fit over 1/4 inch hexhead screws. To mount box, proceed as follows: 1 1 Control Box 2 Push-In Slots (Not Shown) Use slots as template and install screws at desired locations leaving 1/8 inch stickout. 2 Push rear slots firmly against screw heads, and slide box down onto screws. OR Ref. ST-800 156 3-6. Connecting Input Power (T Models) Operate spot welder from a separately fused or circuit breaker protected circuit, and use correct size input conductors. 5 4 1 Rating Label (Not Visible As Shown On Spot Welder) 2 Cord 3 Parallel Plug On 110 Volts AC Models 4 Tandem Plug On 220 Volts AC Models 1 3 OR 1 Do not cut ground terminal off plug. 2 5 Grounded Receptacle Connect plug to grounded receptacle. Model Input Conductor Size (AWG) Fuse/Circuit Breaker Size In Amperes 1.5 kVA 110 Volt No. 10 30 1.5 kVA 220 Volt No. 12 15 2.5 kVA 220 Volt No. 10 30 matching Ref. ST-800 156 OM-716 Page 10 3-7. Connecting Input Power (Non-T Models) Y Input power supply wiring and receptacle must meet National Electrical Code and all other code requirements. 5 3 4 Or 1 2 Operate spot welder from a separately fused or circuit breaker protected circuit, and use correct size input conductors. 1 Rating Label 2 Cord 3 Parallel Plug On 110 Volts AC Models 4 Tandem Plug On 220 Volts AC Models Do not cut ground terminal off plug. 5 Grounded Receptacle Connect plug to grounded receptacle. Model Input Conductor Size (AWG) Fuse/Circuit Breaker Size In Amperes 1.5 kVA 110 Volt No. 10 30 2.5 kVA 220 Volt No. 10 30 matching Ref. ST-800 156 OM-716 Page 11 SECTION 4 – OPERATION 4-1. Controls (T Models) 1 Spot Weld Timer And Pilot Light Weld time adjusts from 0 to 5 seconds. The pilot light turns on when the weld cycle begins and off when the cycle ends. 2 1 Hand Lever Use lever to open and close tongs. Close the hand lever during the welding process to compress the material between the tips. To adjust tong pressure, see Section 3-3. 4 3 2 Start Switch Move start switch sideways in either direction to start weld cycle. When weld cycle time ends, or the start switch is released, weld output stops, and the timer resets for another weld cycle. 4 Power Switch 3 ST-146 013-A 4-2. Controls (Non-T Models) 1 Hand Lever Use lever to open and close tongs. Close the hand lever during the welding process to compress the material between the tips. To adjust tong pressure, see Section 3-3. 2 Start Switch Use switch to turn weld current On and Off. Move switch sideways in either direction to start weld current. Release switch to stop weld current. 1 2 ST-145 104 OM-716 Page 12 SECTION 5 – MAINTENANCE AND TROUBLESHOOTING 5-1. Routine Maintenance Y Disconnect power before maintaining. Every Use 3 Months 6 Months Replace Unreadable Labels Inspect Tips Blow Off Or Vacuum Unit OR During Heavy Service, Clean Monthly 5-2. Overload Protection For 220 Volts Model Y Turn Off unit and disconnect input power. If fuse opens, unit shuts down. To replace fuse, proceed as follows: 1 Fuse Holder Cover 2 Fuse F1 (See Parts List) 1 2 Ref. ST-800 233 / Ref. ST-800 185-A 5-3. Troubleshooting Trouble No weld output. Remedy Check line fuses, and replace if necessary. For 220 V models, check fuse F1, and replace if necessary (see Section 5-2). Low weld output. Dress or replace tips (see Section 3-1). Check tip threads. Replace tips if necessary (see Section 3-1). Remove and clean tongs (see Section 3-2). OM-716 Page 13 Trouble Remedy Clean ends of tongs and tong holders (see Section 3-2). Check power switch (T models only) and/or start switch. Replace if necessary. Longer than normal weld time required. Dress or replace tips (see Section 3-1). Clean workpieces. Adjust tong pressure (see Section 3-3). Clean ends of tongs and tong holders (see Section 3-2). Check input line voltage. Burn through at point of weld. Shorten weld time (see Section 4-1). Adjust tong pressure (see Section 3-3). Dress or replace tips (see Section 3-1). Realign tips (see Section 3-2). OM-716 Page 14 SECTION 6 – ELECTRICAL DIAGRAMS SA-162 466-B Figure 6-1. Circuit Diagram For 110 Volts T-Models SA-072 065-B Figure 6-2. Circuit Diagram For 220 Volts T-Model OM-716 Page 15 SA-162 467-B Figure 6-3. Circuit Diagram For 110 And 220 Volts Non-T Models OM-716 Page 16 Notes OM-716 Page 17 SECTION 7 – PARTS LIST . Hardware is common and not available unless listed. 17 11 9 7 6 10 3 18 10 19 12 8 13 14 15 20 16 5 21 22 23 4 3 31 2 17 30 1 32 19 29 28 46 3 27 45 33 37 36 35 25 24 26 34 38–Fig 6–2 42 43 41 40 39 44 ST-145 048-C Figure 7-1. Main Assembly OM-716 Page 18 Item No. Dia. Mkgs. Part No. Description Quantity Model 41,41T 42,42T 52,52T Figure 7-1. Main Assembly . . . 1 . . . . . . . . . . . . . 019 643 . . HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . 1 . . . . . . . . . . . . . 019 646 . . HANDLE, carrying . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . . . . . . . . . . 601 865 . . NUT, stl hex full fnsh .250-20 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 3 . . . . . . . . . . . . . 602 009 . . SCREW, cap stl sch .250-20 x 1.250 . . . . . . . . . . . . . . . . . 7 . . . . 7 . . . . . . . 4 . . . . . . . . . . . . . 023 660 . . WIRING HARNESS, switch . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 5 . . . . . . . . . . . . . 023 199 . . LEVER, operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . 5 . . . . . . . . . . . . . 082 090 . . LEVER, operating . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 . . . . . . . . . . . . . 010 714 . . PIN, spring CS .312 x 1.750 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 7 . . . . . . . . . . . . . 010 712 . . LINK, tgl connecting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . . . . 8 . . . . . . . . . . . . . 010 713 . . PIN, spring CS .312 x 1.250 . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 9 . . . . . . . . . . . . . 010 715 . . BOLT, pressure adjustment . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 10 . . . . . . . . . . . . . 601 876 . . NUT, stl hex jam .437-20 . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . . . . 11 . . . . . . . . . . . . . 010 668 . . SCREW, cap stl sch .250-20 x 1.500 . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . . . . 12 . . . . . . . . . . . . . 017 668 . . HOLDER, tong top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 13 . . . . . . . . . . . . . 010 709 . . CLAMP, tong top . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 14 . . . . . . . . . . . . . 010 623 . . BRAID, tong set of four . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 15 . . . . . . . . . . . . . 010 716 . . CLAMP, connecting top tong braid . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 16 . . . . . . . . . . . . . 602 008 . . SCREW, .250-20 x 1.000soc hexhd . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . . . . . 17 . . . . . . . . . . . . . 602 262 . . HANDLE, wood . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 18 . . . . . . . . . . . . . 024 130 . . BRACKET, mtg handle . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . 19 . . . . . . . . . . . . . 601 778 . . BOLT, crg stl .250-20 x 4.500 . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 20 . . . . . . . . . . . . . 601 854 . . NUT, al hex .375-24 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . . . . 21 . . . . . . . . . . . . . 095 297 . . STUD, stl .375-24 x 3.750 . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 22 . . . . . . . . . . . . . 026 607 . . GUARD, spatter . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 23 . . . . . . . . . . . . . 128 237 . . SCREW, 10-32 x .500hexwhd slt stl . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . . . . 24 . . . . . . . . . . . . . 070 017 . . INSULATION, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 25 . . . . S1 . . . . . *011 746 . . SWITCH, control (consisting of) . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 011 291 . . . . CONTACT, assembly switch . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . 023 987 . . . . CONTACT, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . . 011 292 . . . . TOGGLE, switch . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . . . . . . . . . . . . . . . . . 070 035 . . . . BASE . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 26 . . . . . . . . . . . . . 122 210 . . SCREW, 10-32 x .625hexwhd slt stl . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . . . . 27 . . . . . . . . . . . . . 026 759 . . INSULATOR, plug sec scr . . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . . . . 28 . . . . . . . . . . . . . . 010 711 . . PIN, spring .375-3.00 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 29 . . . . . . . . . . . . . 169 122 . . HOUSING, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 30 . . . . . . . . . . . . . . . . . . . . . . . . NAMEPLATE (order by model and style number) . . . . . . 1 . . . . 1 . . . . . . . 31 . . . . . . . . . . . . . 602 024 . . SCREW, drive U 2 x 3/16 . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . . . . . 32 . . . . . . . . . . . . . 010 708 . . RETAINER, clamp tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 33 . . . . . . . . . . . . . 026 605 . . INSULATION, bottom clamp . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 34 . . . . . . . . . . . . . 181 179 . . INSULATION, tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 35 . . . . . . . . . . . . . 602 004 . . SCREW, cap stl sch .250-20 x .750 . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . . . . 36 . . . . . . . . . . . . . 010 707 . . CLAMP, bottom tong . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 37 . . . . . . . . . . . . . 039 052 . . CLAMP, threaded connecting tong braid (included w/Item 5, Fig 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 38 . . . . T1 . . . . +095 345 . . TRANSFORMER, pwr main (Fig 6-2) . . . . . . . . . . . . . . . . 1 . . . 38 . . . . T1 . . . . +095 350 . . TRANSFORMER, pwr main (Fig 6-2) . . . . . . . . . . . . . . . . . . . . . . . 1 . . . 38 . . . . T1 . . . . +095 354 . . TRANSFORMER, pwr main (Fig 6-2) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 143 140 . . LABEL, warning general precautionary . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 39 . . . . . . . . . . . . . 600 675 . . SPLICE, butt 16-14 wire . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 40 . . . . . . . . . . . . . . 111 630 . . SCREW, 10-32 x .250hexwhd slt stl . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 41 . . . . . . . . . . . . . 019 642 . . COVER . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 . . . . . . . 42 . . . . . . . . . . . . . 601 847 . . NUT, stl slflkg hex mscr 10-32 . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . . . . . 43 . . . . . . . . . . . . . 134 900 . . STRAIN RELIEF, cable flexible .270-.480 cable . . . . . . . . 1 . . . . 1 . . . . . . . 44 . . . . . . . . . . . . . 094 503 . . CABLE, pwr 10ft 16ga 3/C (Not Req On T Models) . . . . 1 . . . 44 . . . . . . . . . . . . . 094 504 . . CABLE, pwr 10ft 16ga 3/C (Not Req On T Models) . . . . . . . . . . . 1 . . . . . . . 45 . . . . . . . . . . . . . 026 763 . . TUBING, gl acrylic No. 7 x 2.500 . . . . . . . . . . . . . . . . . . . . 3 . . . . 3 . . . . . . . 46 . . . . . . . . . . . . . 128 237 . . SCREW, 10-32 x .500hexwhd slt stl . . . . . . . . . . . . . . . . . . 2 . . . . 2 . . . . 1 1 7 1 1 1 2 1 1 2 3 1 1 1 1 4 1 1 2 1 1 2 1 1 1 1 1 1 2 2 1 1 1 4 1 1 1 2 1 1 1 1 1 1 1 4 1 1 3 2 *Recommended Spare Parts. +When ordering a component originally displaying a precautionary label, the label should also be ordered. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and style number required when ordering parts from your local distributor. OM-716 Page 19 Replace Coils At Factory Or Factory Authorized Service Station. Item No. Part No. Quantity Model 41,41T 42,42T 52,52T Description Figure 7-2. Transformer, Power Main (Fig 7-1 Item 38) ... ... ... ... ... ... ... ... ... ... 1 1 2 2 2 3 3 4 5 5 . . . . . . . 026 601 . . . . . . . 026 602 . . . . . . . 095 312 . . . . . . . 095 309 . . . . . . . 095 308 . . . . . . . 010 157 . . . . . . . 010 156 . . . . . . . 137 943 . . . . . . +033 123 . . . . . . +033 122 .. .. .. .. .. .. .. .. .. .. 095 345 095 350 095 354 INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 INSULATION . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . COIL, pri 115V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 COIL, pri 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 COIL, pri 230V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STUD, stl No. 10-32 x 8.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 STUD, stl No. 10-32 x 11.125 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . NUT, core stud . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 . . . . 4 . . . . BAR, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . 1 BAR, sec . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1 4 4 1 1 2 3 4 5 . Hardware is common and not available unless listed. ST-141 482-A Figure 7-2. Transformer, Power Main +Item 37 on Figure 7-1 is included when ordering these items as replacement parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and style number required when ordering parts from your local distributor. OM-716 Page 20 Item No. Dia. Mkgs. Description Quantity Model 115V 230V Figure 7-3. Timer, Spot (230V Illustrated) 041 081 041 082 Part No. ... 1 ........................ . . . 2 . . . . S1 . . . . . . 124 511 . . . . . 3 . . . . . W . . . . . 194 307 . . . . . . . . . . . . . . . . . . . . . 188 210 . . . . . 4 . . . . . . . . . . . . . 032 152 . . . . . 5 . . . . T2 . . . . . 605 856 . . . . . 6 . . . . . . . . . . . . . 168 308 . . . . . 7 . . . . TD1 . . . . 605 952 . . . . . 8 . . . . . . . . . . . . . 046 432 . . . . . 9 . . . . F1 . . . . . *012 653 . . . . . 10 . . . . . . . . . . . . . 087 179 . . . . . 11 . . . PLG1 . . . 096 822 . . . . . 11 . . . PLG1 . . . 096 481 . . . . . 12 . . . . . . . . . . . . . 134 900 . . NAMEPLATE, (order by model and style numbers) . . . . . . . . . . . . . 1 . . . . SWITCH, tgl DPST 40A 600VAC . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . CONTACTOR, 40A 3P (consisting of) . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . LINK, connecting contactor terminal . . . . . . . . . . . . . . . . . . . . . . . . . 2 . . . . CABINET . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . TRANSFORMER, control 230/460 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . PANEL, front . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . TIMER, delay reset 5sec 120V . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . HOLDER, fuse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . FUSE, mintr gl .5A . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . CABLE, interconnecting 10ft . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 . . . . CABLE, pwr 10ft 16ga 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 CABLE, pwr 10ft 16ga 3/c . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . STRAIN RELIEF, cable flexible .270-.480 cable . . . . . . . . . . . . . . . . 2 . . . . 3 2 1 1 1 2 1 1 1 1 1 1 1 1 2 4 1 12 11 5 6 10 9 8 7 ST-146 012-E Figure 7-3. Timer, Spot (230V Illustrated) *Recommended Spare Parts. To maintain the factory original performance of your equipment, use only Manufacturer’s Suggested Replacement Parts. Model and style number required when ordering parts from your local distributor. OM-716 Page 21 Chart 7-1. Spot Welder Tips 3-1/2” (89 mm) STANDARD 3-1/2” (89 mm) MO OFFSET 6-1/2” (165 mm) 6” (152 mm) 040 197 12” (305 mm) 040 198 Standard Flat 18” (457 mm) 040 199 040 211 6” (152 mm) 040 200 12” (305 mm) 040 201 040 212 MO Offset 18” (457 mm) 040 202 040 215 12” (305 mm) 040 203 Standard Flat 18” (457 mm) 040 204 TT-6 9-1/2” (241 mm) 040 211 12” (305 mm) 040 205 Standard 040 212 Flat 18” (457 mm) 040 206 040 211 TT-9 7-1/2” (190 mm) 8” (203 mm) 040 207 8” (203 mm) 040 208 040 213 5” (127 mm) 040 209 OM-716 Page 22 040 212 FF FF FH Flat Standard 040 211 G-7 040 212 FH 040 214 S-0550 Effective January 1, 2000 (Equipment with a serial number preface of “LA” or newer) This limited warranty supersedes all previous Miller warranties and is exclusive with no other guarantees or warranties expressed or implied. Warranty Questions? Call 1-800-4-A-MILLER for your local Miller distributor. Your distributor also gives you ... Service You always get the fast, reliable response you need. Most replacement parts can be in your hands in 24 hours. Support Need fast answers to the tough welding questions? Contact your distributor. The expertise of the distributor and Miller is there to help you, every step of the way. * LIMITED WARRANTY – Subject to the terms and conditions below, Miller Electric Mfg. Co., Appleton, Wisconsin, warrants to its original retail purchaser that new Miller equipment sold after the effective date of this limited warranty is free of defects in material and workmanship at the time it is shipped by Miller. THIS WARRANTY IS EXPRESSLY IN LIEU OF ALL OTHER WARRANTIES, EXPRESS OR IMPLIED, INCLUDING THE WARRANTIES OF MERCHANTABILITY AND FITNESS. Within the warranty periods listed below, Miller will repair or replace any warranted parts or components that fail due to such defects in material or workmanship. Miller must be notified in writing within thirty (30) days of such defect or failure, at which time Miller will provide instructions on the warranty claim procedures to be followed. Miller shall honor warranty claims on warranted equipment listed below in the event of such a failure within the warranty time periods. All warranty time periods start on the date that the equipment was delivered to the original retail purchaser, or one year after the equipment is sent to a North American distributor or eighteen months after the equipment is sent to an International distributor. 1. 5 Years Parts – 3 Years Labor * * 2. 3 Years — Parts and Labor * * * * * * 3. Original main power rectifiers Inverters (input and output rectifiers only) Transformer/Rectifier Power Sources Plasma Arc Cutting Power Sources Semi-Automatic and Automatic Wire Feeders Inverter Power Supplies Intellitig Engine Driven Welding Generators (NOTE: Engines are warranted separately by the engine manufacturer.) 1 Year — Parts and Labor * * * * * * * * * * * * * * * * * DS-2 Wire Feeder Motor Driven Guns (w/exception of Spoolmate 185 & Spoolmate 250) Process Controllers Positioners and Controllers Automatic Motion Devices RFCS Foot Controls Induction Heating Power Sources Water Coolant Systems HF Units Grids Maxstar 140 Spot Welders Load Banks Miller Cyclomatic Equipment Running Gear/Trailers Plasma Cutting Torches (except APT & SAF Models) Field Options (NOTE: Field options are covered under True Blue for the remaining warranty period of the product they are installed in, or for a minimum of one year — whichever is greater.) 4. 6 Months — Batteries 5. 90 Days — Parts * * MIG Guns/TIG Torches Induction Heating Coils and Blankets * * * * * APT, ZIPCUT & PLAZCUT Model Plasma Cutting Torches Remote Controls Accessory Kits Replacement Parts (No labor) Spoolmate 185 & Spoolmate 250 Canvas Covers Miller’s True Blue Limited Warranty shall not apply to: 1. Consumable components; such as contact tips, cutting nozzles, contactors, brushes, slip rings, relays or parts that fail due to normal wear. 2. Items furnished by Miller, but manufactured by others, such as engines or trade accessories. These items are covered by the manufacturer’s warranty, if any. 3. Equipment that has been modified by any party other than Miller, or equipment that has been improperly installed, improperly operated or misused based upon industry standards, or equipment which has not had reasonable and necessary maintenance, or equipment which has been used for operation outside of the specifications for the equipment. MILLER PRODUCTS ARE INTENDED FOR PURCHASE AND USE BY COMMERCIAL/INDUSTRIAL USERS AND PERSONS TRAINED AND EXPERIENCED IN THE USE AND MAINTENANCE OF WELDING EQUIPMENT. In the event of a warranty claim covered by this warranty, the exclusive remedies shall be, at Miller’s option: (1) repair; or (2) replacement; or, where authorized in writing by Miller in appropriate cases, (3) the reasonable cost of repair or replacement at an authorized Miller service station; or (4) payment of or credit for the purchase price (less reasonable depreciation based upon actual use) upon return of the goods at customer’s risk and expense. Miller’s option of repair or replacement will be F.O.B., Factory at Appleton, Wisconsin, or F.O.B. at a Miller authorized service facility as determined by Miller. Therefore no compensation or reimbursement for transportation costs of any kind will be allowed. TO THE EXTENT PERMITTED BY LAW, THE REMEDIES PROVIDED HEREIN ARE THE SOLE AND EXCLUSIVE REMEDIES. IN NO EVENT SHALL MILLER BE LIABLE FOR DIRECT, INDIRECT, SPECIAL, INCIDENTAL OR CONSEQUENTIAL DAMAGES (INCLUDING LOSS OF PROFIT), WHETHER BASED ON CONTRACT, TORT OR ANY OTHER LEGAL THEORY. ANY EXPRESS WARRANTY NOT PROVIDED HEREIN AND ANY IMPLIED WARRANTY, GUARANTY OR REPRESENTATION AS TO PERFORMANCE, AND ANY REMEDY FOR BREACH OF CONTRACT TORT OR ANY OTHER LEGAL THEORY WHICH, BUT FOR THIS PROVISION, MIGHT ARISE BY IMPLICATION, OPERATION OF LAW, CUSTOM OF TRADE OR COURSE OF DEALING, INCLUDING ANY IMPLIED WARRANTY OF MERCHANTABILITY OR FITNESS FOR PARTICULAR PURPOSE, WITH RESPECT TO ANY AND ALL EQUIPMENT FURNISHED BY MILLER IS EXCLUDED AND DISCLAIMED BY MILLER. Some states in the U.S.A. do not allow limitations of how long an implied warranty lasts, or the exclusion of incidental, indirect, special or consequential damages, so the above limitation or exclusion may not apply to you. This warranty provides specific legal rights, and other rights may be available, but may vary from state to state. In Canada, legislation in some provinces provides for certain additional warranties or remedies other than as stated herein, and to the extent that they may not be waived, the limitations and exclusions set out above may not apply. This Limited Warranty provides specific legal rights, and other rights may be available, but may vary from province to province. miller_warr 7/00 Owner’s Record Please complete and retain with your personal records. Model Name Serial/Style Number Purchase Date (Date which equipment was delivered to original customer.) Distributor Address City State Zip For Service Call 1-800-4-A-Miller or see our website at www.MillerWelds.com to locate a DISTRIBUTOR or SERVICE AGENCY near you. Always provide Model Name and Serial/Style Number. Contact your Distributor for: Welding Supplies and Consumables Options and Accessories Personal Safety Equipment Service and Repair Miller Electric Mfg. Co. An Illinois Tool Works Company 1635 West Spencer Street Appleton, WI 54914 USA Replacement Parts Training (Schools, Videos, Books) International Headquarters–USA USA Phone: 920-735-4505 Auto-Attended USA & Canada FAX: 920-735-4134 International FAX: 920-735-4125 Technical Manuals (Servicing Information and Parts) Circuit Diagrams European Headquarters – United Kingdom Phone: 44 (0) 1204-593493 FAX: 44 (0) 1204-598066 Welding Process Handbooks www.MillerWelds.com Contact the Delivering Carrier for: File a claim for loss or damage during shipment. For assistance in filing or settling claims, contact your distributor and/or equipment manufacturer’s Transportation Department. PRINTED IN USA 2001 Miller Electric Mfg. Co. 1/01
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